A Seminar on

Abrasive Jet Machining (AJM)

 Abrasive Jet Machining (AJM)
 It is a material removal process where the material is removed (or machined) by
the impact erosion of high velocity stream of air (or gas) and abrasive mixture,
which is focused onto the workpiece.

 In other words, in Abrasive Jet Machining (AJM), abrasive particles are made to
impinge on the workpiece at high velocity. The high velocity abrasive particles
remove the material by micro-cutting action as well as brittle fracture of the work
material.

 This method can also be referred as ‘abrasive micro-blasting’ or ‘pencil blasting’

or ‘micro-abrasive blasting’.

 The pressurized air discharges to assist abrasives towards machining (erosion)

process. Abrasive particles are typically of 0.025 mm in diameter.

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Overall arrangement of AJM unit :

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 Mechanics of material removal in AJM –
 Abrasive particles impinge on the work surface at a high velocity and this impact causes
tiny brittle fracture and the following air (or gas) carries away dislodged small workpiece
particles (debris).

 The kinetic energy of the abrasive particles should be sufficient to favor material removal
due to brittle fracture of the workpiece or even micro-cutting by abrasives.

 The material removal in AJM is based upon the following assumptions –

 Abrasives are spherical in shape and rigid. The particles are characterized by the mean grit
diameter.

 The kinetic energy of the abrasives are fully utilized in removing material.

 Brittle materials are considered to fail due to brittle fracture and the fracture volume is
considered to be hemispherical.

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 The material removal rate (Q) in AJM can be expressed by the following expression –
where, K = a constant,
Z = no. of abrasive particles impacting per unit time.
d = mean diameter of abrasive grains,
Q = K Z d3v1.5(ρ/12Hw)0.75
v = velocity of abrasive grains,
p = density of abrasives,
Hw = hardness of the work material

ABRASIVE GRAIN
FRACTURED WORK-PART

FRACTURE CAVITY

WORK-PART WORK-PART

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 The process characteristics can be evaluated by considering the following –

 the Material Removal Rate (MRR)

 the geometry of the cut portion
 the roughness of the surface produced
 the rate of nozzle wear

 The major process parameters which control the above quantities are –

 The abrasive (composition, strength, size and mass flow rate)

 The gas (composition, pressure and velocity)
 The nozzle (geometry, material, distance from and inclination to the work surface)

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 Different process parameters and machining characteristics –

Abrasive: Material – Al2O3/ SiC / glass beads Abrasive Jet : Velocity – 100 ~ 300 m/s

Shape – irregular / spherical Mixing ratio – mass flow ratio of abrasive to

Size – 10 ~ 50 μm gas

Mass flow rate – 2 ~ 20 gm/min Stand-off distance – 0.5 ~ 5 mm

Impingement Angle – 60 ~ 90

Carrier gas: Composition – Air, CO2, N2

Density – Air ~ 1.3 kg/m3 Nozzle: Material – WC

Velocity – 500 ~ 700 m/s Diameter (Internal) – 0.2 ~ 0.8 mm

Pressure – 2 ~ 10 bar Life – 10 ~ 300 hours

Flow rate – 5 ~ 30 lpm

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 Advantages –

 As no contact between the nozzle and workpiece, machining is free from vibrations (chatters).
 Almost null heat affected zones can be found; hence no work-hardening tendency.
 By selecting proper size of abrasives a better surface finish can be achieved.
 Thin sections of brittle and hard materials (ceramic, glass, germanium etc.) and heat sensitive
materials can be easily machined.
 Drilling of intricate holes is possible and low capital investment for machining.

 Limitations –
 Low material removal rate and chances of air pollution is a risk factor.
 Abrasives aren’t reusable as cutting ability decreases and chances of clogging increases.
 Higher chances of stray cutting and tapering of drilled holes.
 A short Stand-off-Distance leads to decrease in nozzle life (usually 300 h).

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 Some applications of AJM –
 Can be used to remove oxides on metals, resistive coatings from surfaces.
 Employed in deburring of plastic, cutting of metal-foils, frosting (roughened matte finish) of shiny
materials, machining of superalloys and refractory materials.
 Helps in removal of parting lines from injection moulded parts.
 Deburring of minute precision parts, which require burr free finishing such as medical appliances,
hydraulic valves and air-craft fuel systems.
 Polishing of nylon and Teflon components are also possible.
 Applied for trimming and bevelling.
 Engravement of permanent marks on material surfaces can be done by this method.

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AJM Parametric Effect. .

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